Safety thermostatic control for marine engine cooling systems



United States Patent 3,096,022 SAFETY 'IHERMOSTATIC CONTROL FOR MARINEENGINE COGLING SYSTEMS Donald A. Holley, 790 E. Bremer Ave, Waverly,Iowa Filed Dec. 2, 1959, Ser. No. 856,685 7 Claims. (Cl. 236-345) Thisinvention relates to improvements in thermostatic controls for marineengine cooling systems and is directed more particularly to a new andnovel type of safety valve.

In my prior Patent Nos. 2,536,642 and 2,757,650, I disclose athermostatic control for marine engine cooling systems, wherein water istaken in from the body supporting the boat in which the marine engine iscarried and is directed into the engine water jacket and also through acontrol valve unit, passing from the unit directly back to the sourcefrom which it is taken. This control valve unit embodies a normallyseated poppet which in its closed position substantially blocks thepassage of water from the engine jacket permitting a major portion ofthe water from the pump to bypass the heat sensitive unit housingchamber and permitting only a very small fraction of the water from theengine jacket to enter the chamber having the heat sensitive unittherein. Under normal conditions of operation of the engine the engineblock heats up slowly and slowly increases the temperature of the waterpassing therethrough so that as this gradually heating water from theengine block passes through the heat sensitive unit containing chamber,the unit responds by gradually opening the valve to permit more and moreof the heated water to pass around the unit and at the same timegradually shuts oi the flow of the water directly from the pump line tothe return or discharge passage. Eventually the valve shifts the poppetportion which is actuated by the heat sensitive unit to a position Wherethe full flow of water from the engine jacket passes around the heatsensitive unit and the flow from the pump directly to the outlet is shutoff.

In my patents above referred to there is disclosed the use of a bellowstype of thermostatic or heat responsive device such as that known as theSylphon bellows, which employs a highly volatile liquid having theaction of expanding rapidly under the influence of a rise in temperatureof the water surrounding the unit. Other types of heat sensitive unitsmay be employed in this capacity, but in any case such units respondrather rapidly to a temperature rise.

In systems of the character to which the present thermostatic controldevice is employed, conditions frequently arise or are created whichresult in a very rapid reaction of the heat sensitive material in thethermostat, causing the thermostatically actuated poppet to move againsta seat which shuts oil the flow of water from the discharge side of thepump. As an example, when an engine is started up, if it is rapidlyaccelerated, the escape means for the engine jacket water to thedischarge line cannot carry off the water and the temperature of thelatter builds up rapidly so that a more or less violent reaction in theheat sensitive element of the thermostat occurs, forcing thethermostatically actuated poppet onto its seat and if no relief isprovided for the continued increase of pressure exerted by the heatsensitive material of the unit, the result is severe damage to the unit.

In the light of the foregoing it is a particular object of the presentinvention to provide .a new and novel thermostatic control for a marineengine cooling system which is designed in a novel manner whereby anyoverheating of the thermostatic unit or heat sensitive material of theunit will not result in the permanent damage of the unit.

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novel supporting means for the active element of the unit whereby thethrust of the unit when opposed by the seating of a poppet valveactuated thereby, will result in a reverse movement of the unit to yieldand absorb the thrust action and thereby prevent damage to the unit.

Another object of the invention is to provide a novel yieldable supportmeans for a heat sensitive unit of a type wherein the thermal element iscomprised of a powdered copper and wax compound permanently encased inan expansion chamber and exerting when expanded under the application ofheat, thrust against a valve actuating piston, whereby such supportpermits a reverse movement of the thermal element container when thepoppet actuating piston is checked in its movement by the result of thepoppet seating against an immovable seat.

The invention will be best understood from consideration of thefollowing detail description taken in connection with the accompanyingdrawing forming part of the specification, with the understanding,however, that the invention is not confined to a strict conformity withthe showing of the drawing but may 'be changed or modified so long assuch changes or modifications mark no material departure from thesalient features of the invention as expressed in the appended claims.

In the drawings:

FIG. 1 is a sectional View through the thermostatic control unit, inclosed position, showing the connections therewith of water conduitsleading to diagrarnrned engine cooling system connections correspondingto those shown in my prior patents referred to and showing the heatsensitive element and spring thereof in elevation;

FIG. 2 is a view corresponding to FIG. 1 but showing the unit in openposition and illustrating the relative position of the parts underexcessive heating of the heat responsive element;

FIG. 3 is a detail view on an enlarged scale of the element and itssupporting means removed from the housing with the thermal element andpiston housing in section;

FIG. 4 is a sectional view taken substantially on the plane of sectionline 44 of FIG. 1 and showing the poppet supporting pipes upon which theedge of the poppet rests in valve-closed position;

FIG. 5 is a view in perspective of the element for coupling the lowerends of the poppet return springs with the bottom of the heat responsiveelement;

FIG. 6 is a View looking at the underside of the poppet and showing themeans for connecting the upper ends of the poppet return springstherewith.

Referring now more particularly to the drawing, the numeral 10 generallydesignates the safety thermostatic control device or unit of the presentinvention.

This unit comprises a housing having the two parts 12 and 14 which, forconvenience of description, will be referred to as the upper and loweror first and second chamber parts although it will be understood that byreferring to upper and lower parts it is not the intention to conveythat the device must be used in this position since it can function inthe inverted position from which it is shown in FIG. 1 or in any otherdesired position.

The parts 12 and 14 provide a poppet chamber 16 and a heat sensitiveelement encasing chamber 18.

The reference characters A, B and C designate pipelines or pipelineconnections leading, respectively, from the internal combustion enginecylinder head, the discharge side of the water pump by which water istaken in from a source and circulated into and through the engine waterA further object of the invention is to provide in a thermostaticcontrol unit of the character referred to, a

jacket, and the exhaust stack or overboard outlet by way of which thewater passes back to its source from the engine.

Only a diagrammatic illustration of the engine water jacket, the pumpand the exhaust stack, is here shown in association with these pipes orconduits A, B and C. It

. a 3 is believed that the operation of the present invention inassociation therewith will be clearly understood and refer ence may behad to my herei-nbefore referred-to patents torfurther disclosure of theparts with which these pipes or conduits are connected.

The upper or first part 12 of the housing is provided with the Waterinletport with which the pipe or conduit B is connected and, as shown,this port is located in the axial center or the housing and is directeddownwardly toward the center of the chamber 18.

At one side of the port 24 is a second threaded port 22 in which theconduit C leading to the exhaust stack is connected so that it will beapparent that water entering the chamber 16 by way of the conduit B mayflow under proper conditions through the chamber to and out through theconduit C.

The wall 24 of the second or lower part 14 of the housing is likewiseprovided with a threaded port 26 in which is connected a pipe or conduitA leading from the engine jacket oricylinder head.

. The upper and lower parts 12 and 14 have opposing ooupilinglfaces 23and 30 respectively which are adapted to be secured together in asuitable manner as by means of bolts 31 and between which a peripheralpart of the heat sensitive element and poppet supporting plate issecured. a

The numeral 32 designates. an annular plate having a ribbed peripheralportion 33 which is secured between the faces 28 and 30 and between atleast one of these fiaces and the secured peripheral portion of theplate is a gasket 34, the rib 33. projecting upwardly and forming atight seat. or contact with the face 28 of the top part 12.

.Theopening in the plate 32 is designated 35 and there is suspended fromthe plate a spider embodying a number otdownwardfly converging arms 36each joining the plate 52 at theedge of the opening 35 and connected attheir lower ends with the thrust absorbing spring supporting ring 37. v

.The annular plate 32 is formed with several upstanding pips or buttons38, here shown as three in number, and these project only. a very smalldistance above the surface of the plate, as, for example, in theneighborhood of 0.006 of an inch.

The numeral 39 generally designates a solid fill pellet type heatresponsive member of a standard or known type which embodies a chamberedbody portion 40 leading into a tubular neck 41, in the upper end ofwhich is slidably positioned a thrust piston 42.. The chamber 43 in theportion 4% contains a powdered copper-wax compound 44 forming thethermal substance or heat responsive substance and interposed betweenthe top of this substance in the neckAl, and the piston 42, is a rubberdiaphragm 45. Upon the application of. heat to the body. 40 the compound44 expand and imposes an upward thrust on the piston through the mediumof the interposed diaphragm 45.

As illustrated, the body 40 is of larger outside diameter than the neck41 so that there is thus provided a shoulder 46 and the neck 41 extendsthrough the ring 37 which normally rests upon this shoulder 46.

.The neck 41 also passes through a thrust absorbing spring 47 which atits lowerend rests upon the ring 37 while atits upper end it is pressedagainst a collar 48 which'encircles the top end of the neck and is heldin place in a suitable'm anner as, for example, by means of a snap ring49. Thi spring 47 is under constant compression and, therefore, tends topull the heat responsive member 39 upwardly and thereby pull theshoulder 46 of the part 40 against the underside of the ring 37 and alsofunctions, upon excessive heating and expansion of the thermal heatresponsive material 44 and excessive extension of the piston 42, toabsorb the thrust by permitting the thermal compound and piston carryingelement to move back.

The numeral 50 generally designates the poppet which 4 comprises thedisc head 51 and the downturned surrounding flange 52. This poppet asshown i located in the upper chamber 16 with the flange 52 directeddownwardly toward the annular plate 32 and this flange is of the properdiameter to contact or rest upon the pips 38 when the valve is in theclosed position, shown in FIG. 1, thereby providing a narrow waterpassage 53 between the chamber 18 and the chamber 16.

The center of the poppet head 51 has an opening 54 therethrough. Thisopening is provided to receive the reduced terminal portion or stemportion 55 of the piston 42. This stem portion 55 is of suflicientlength to extend into the overlying port 20 beyond'the poppet seat 61.

The poppet is thus free to rise on the reduced terminal portion or stem55 if and when necessary to come into engagement with the seat andwithout, at the same time, becoming misaligned withthe stem. This actionor condition might occur when a sudden injection or surge of water takesplace into the lower or second chamber. Being free from fixed connectionwith the stem, the piston thus would not be drawn upwardly in the neck41 away from the rubber diaphragm.

In starting upthe engine cold, it the engine is speeded up so that sucha sudden surge of Water enters the second chamber, naturally the thermalmaterial or composition 44 would remain unexpanded because such waterwould be cold. Therefore, if the piston were raised under theseconditions and separated from the rubber diaphragm, as stated, a reducedpressure area could be formed between the piston and rubber diaphragmwhich mightresult in V the drawing of water or foreignmatter into sucharea past the piston with resultant injuryto the device. allowing forthe 'free movement of the poppet on the stem, no such condition willarise from the sudden insurge of cold water into the lower chamber andthe application of pressure against the underside ofthe poppet.

The numeral 56 designates poppet return springs which are connectedbetween the poppet 50 and the lower end of the heat responsive member 39in the folflowin g manner.

There is secured against the underside of the poppet head 51 the smallplate 57 which has the outwardly extending hooks 58, the ends of whichare directed to the underside of the head 51, these hooks correspondingin number to the springs 56. The upperend of each of the springs isconnected with one of these hooks 58. The numeral 53 designates a saddleplate which is located beneath and in which rests the bottom end of theheat responsive member 39 and this saddle also carries the outwardlyextending and downturned hock arms 60 to each of which the lower end ofa poppet return spring 56 is tions, from a consideration of my priorpatents hereinbefore referred to, it will'be understood that when thepresout control device is installed for operation in a marine internalcombustion engine, the poppet 56 will be separated from the seat 61which encircles the inner end of the port 20 and :against which theouter'side of the body 51 of the poppet is adapted to engage when it isfully shifted away from the annular plate 32. The' poppet will thus'bein what will be understood as valve-closed position with the peripheryof the flange 52 resting upon the buttons or pips 38.

Under normal working conditions when the engine is started and warmed upin the proper manner, the water from the circulating pump, not shown,will flow by two paths, one leading to the pipe or conduit A and intothe chamber 18 and the other leading to the pipe or conduit B into thechamber 16. A small amount of this water entering the chamber 18 willpass through the passage 53 into the chamber 16' and pass from thischamber with the water entering by way of the port 20 out through thepipe or conduit C. Thus as the engine gradually warms up, the watergradually increasing in temperature will enter the chamber 18 and atfectthe heat responsive compound 44 to extend the piston 42, thus moving thepoppet toward the seat 61. Thus the flow directly from the port 20 tothe port 22 will be gradually shut off and the flow from the port 26into the chamber 18, then to the chamber 16 and from there to the outletport 22 will gradually increase.

During the foregoing operation the poppet return springs 56 will beincreased in tension so that when the engine is stopped and the thermalcompound contracts the poppet will be drawn back to its closed position.

In the event that a sudden or rapid application of heat to the body 40of the heat responsive member takes place through the actionhereinbefore described, by the intensely heated water entering thechamber 18, so that the piston 42 is rapidly projected and the poppetseated to close the port 20, the thrust of the poppet against its seatby the tendency of the piston to continue to move outwardly will beabsorbed by the spring 47 which supports the heat responsive member inthe manner described, thus permitting the parts 40 and 41 of the heatresponsive member to move away from the poppet or reversely with respectto the piston, as illustrated in FIG. 2. Thus the device will beprotected against damage which it would otherwise receive if the heatresponsive member were secured in its entirety against any such reversemovement so that the piston 42 will continue to be forced outwardly andthe poppet 50 would continue to be pressed against its seat by theexpanding thermal compound. Consequently with the above action occurringas described, through the provision of the thrust absorbing spring thepoppet will be held open to permit free flow of water from the enginejacket to the chamber and out through the conduit C until normaloperating conditions are established.

I claim:

1. A thermostatically actuated valve unit comprising a housing, a platemember therein and dividing the housing into a first chamber and asecond chamber, said plate member having a central opening therethrough,a fluid inlet port and a fluid outlet port opening directly into thefirst chamber, a fluid inlet port opening into the second chamber, aspider structure supported by said plate member in said second chamber,a thermal element having a body and a piston carried by the body andmovable relative to the body by thermal action, a resilient meansconnected with said body and supporting the thermal element on thespider, said piston being directed through said plate member opening, avalve poppet positioned within the first chamber over the plate memberand supported by the piston and movable thereby between two extremepositions in one of which positions it engages the plate member over theopening therein, and in the other of which positions it closes the fluidinlet port communicating with the first chamber, said valve poppetembodying an annular flange directed toward said plate member andwherein the plate member carries spaced means forming a part thereofwith which said flange is adapted to engage, whereby a restricted waterpassage is provided between the two chambers, and spring means connectedwith and between the valve poppet and the body portion of the thermalelement and normally urging movement of the valve poppet toward saidplate member.

2. A thermostatically actuated valve unit comprising a housing formed in.at least two parts having confronting peripheral surfaces, a centrallyapertured plate member between said housing parts and secured around andadjacent to its periphery between said confronting surfaces whereby theplate member divides the housing into a first chamber and a secondchamber, a spider carried by the plate member and extending into thesecond chamber and including a ring arranged coaxially with the openingof the plate member, a fluid inlet port opening into the first chamber,a valve seat encircling said fluid inlet port, a fluid outlet portopening into the first chamber, a fluid inlet port opening into thesecond chamber, said opening of the plate member being coaxial with saidvalve seat and the first fluid inlet port, a thermal element having anelongate body comprising a thermally responsive medium containing partand an elongate neck part, said neck part extending through the spiderring and being limited in its movement therethrough by engagement of thering with the said thermal responsive medium containing part, saidthermal element further including a piston carried by and movablerelative to said neck part and extending axially from the latter throughthe opening of said plate member, resilient means encircling said neckpart of the thermal element body and being secured under compressionbetween said spider ring and an element secured to the neck part whereby.to normally urge movement of the thermal body toward the first fluidinlet port, a valve poppet coupled with said piston and located withinthe first chamber and adapted to be moved by the piston between a firstposition in which it engages the plate member and covers the openingtherein and a second position in which it engages the said valve seatand closes said first inlet port upon the extension of the piston inresponse to thermal expansion of the medium in the first mentioned partof the thermal element body, resilient means normally urging thetraction of the piston to bring the valve poppet to said first positionthereof, and said plate member carrying upon its top a number ofupstanding elements disposed around the aperture therein and located ina position to be engaged by the valve poppet in the said first positionof the latter to provide a flow passage between the poppet and theplate.

3. A thermostatically actuated valve unit comprising a housing formed inat least two parts having confronting peripheral surfaces, a centrallyapertured plate member between said housing parts and secured around andadjacent to its periphery between said confronting surfaces whereby theplate member divides the housing into a first chamber and a secondchamber, a spider carried by the plate member and extending into thesecond chamber and including a ring arranged coaxially with the openingof the plate member, a fluid inlet port opening into the first chamber,a valve seat encircling said fluid inlet port, a fluid outlet portopening into the first chamber, a fluid inlet port opening into thesecond chamber, said opening of the plate member being coaxial with saidvalve seat and the first fluid inlet port, a thermal element having anelongate .body comprising a thermally respon sive medium containing partand an elongate neck part, said neck part extending through the spiderring and being limited in its movement therethrough by engagement of thering with the said thermal responsive medium containing part, saidthermal element further including a piston carried by and movablerelative to said neck part and extending axially from the latter throughthe opening of said plate member, resilient means encircling said neckpart of the thermal element body and being secured under compressionbetween said spider ring and an element secured tothe neck part wherebyto normally iirge movement of the thermal body toward the first fluidinlet port, a valve poppet coupled with said piston and located withinthe first chamber and adapted to be moved by the piston between a firstposition in which it engages the plate member and covers the openingtherein and a second position in which it engages said valve seat andcloses said first inlet port upon the extension of the piston inresponse to thermal expansion of the medium in the first mentioned partof the thermal element body, resilient means normally urging thetraction of the piston to bring the valve poppet to said first positionthereof, and the last named resilient means comprising spring elementsconnected at one end to the underside of the poppet and extendingthrough the plate member aperture and connected at their other ends tothe thermal element at the end of the latter on the side of the spiderring-remote from the first named resilient housing, a plate membertherein and dividing the housing into a first chamber and a secondchamber, said plate member having a central opening therethrough, aspider connected with the plate member and supporting a ring disposedwithin the second chamber and concentric with the opening in the platemember, va fluid inlet port and a fluid outlet port opening directlyinto the first chamber, a fluid inlet port opening into the secondchamber, a valve seat encircling the first inlet port and being coaxialwith the spider carried ring, a poppet valve withinthe first chambercomprising a disc head having a top side adapted to engage said valveseat and having an encircling flange projecting from the opposite sidetoward said plate member, the poppet valve being movable between thevalve seat and the plate member, said flange being designed to engagethe plate member in encircling relation with the opening therethroughfor substantially closing the opening, a thermal element comprising abody portion a neck portion and a piston carried by the body portion andmovable relative thereto by thermal action,

said body portion being disposed in the second chamber on the side ofthe ring remote from the poppet valve and the neck portion extendingthrough the ring toward the poppet valve, there being a connectionbetween the piston and the poppet valve, resilient means encircling theneck portion and connected at one end therewith and engaging at itsother end upon said ring, elongate spring elements eachconnected at oneendwith the under side of the poppet valve head and extending into thesecond chamber, and means connecting the other ends of the springelements with the body of the thermal element.

5. A thermostatically actuated valve unit compnising a housing, .a platemember therein and dividing the housing into a first chamber and asecond chamber, said plate member having a central opening therethrough,a spider connected with the plate member and supporting a ring disposedwithin thesecond chamber and concentric with the opening in the platemember, a fluid inlet port and 'a fluid outlet port opening directlyinto the first chamber, a fluid inlet port opening into the secondchamber, a valve seat encircling the first inlet port and being coaxialwith the spider carried ring, a poppet valve within the first chambercomprising a disc having a top side adapted to engage said valve seatand having an encircling fiange projecting from the opposite side towardsaid platetrnember, the poppet valve being movable between the valveseat and the plate memben said flange being designed to engage the platemember in encircling engagement with the opening therethrough forsubstantially closing the opening, a thermal element comprising a bodyportion, a neck portion and a piston carried by the body portion andmovable relative thereto by thermal action, said body portion beingdisposed in the second chamber on the side of the ring remote \from thepoppet valve and the neck portion extending through the ring toward thepoppet valve, there being a connectionbetween the piston and the poppetvalve, resilient means encircling the neck portion andrconnected at oneend therewith and engaging at its other end upon said ring,

hook elements secured to the under side of the poppet valve disc head inencircling relation with the thermal element piston, a plurality ofelongate spring elements each having an end connected with a hookelement and extending therefrom into the second chamber, a'saddle platehaving said thermal element body resting thereagainst on the side of thebody remote from said neck portion, said saddle plate including aplurality of hook elements and each of said spring elements having itsother end connected with a hook element or the saddle plate.

6. A valve unit of the character stated in claim 4, wherein said poppetvalve disc head has a central opening therethrough and the saidconnection between the piston and the disc head comprises a stemextending axially of and from the 'end'of the .piston adjacent to the ahead and passing through the said opening in the head and free of fixedconnection with the head whereby 'the poppet valve has limited freemovement on the stem.

7. A thermostatically actuated valve unit comprising a housing, a' platemember therein 'and dividing the housing into a first chamber and asecond chamber, said plate member having a central opening therethrough,a spider connected with the plate member and supporting a ring disposedwithin the second chamber and concentric with the opening in the platemember, a fluid inlet port and a fluid outlet port opening directly intothe first chamber, a fluid inlet port opening into the second chamber, apoppet valve within the first chamber comprising a disc head having'anencircling flange projecting towards said plate member, the poppet'valvebeing movable in the first chamber relative to the plate member,there being means in the first chamber engageable by said disc head forlimiting movement of the poppet valve away the side of the ring remotefrom the poppet valve and the neck portion extending through the ringtoward the poppet valve, there being a connection between the piston andthe poppet valve, resilient means encircling the neck portion andconnected at one end therewith and engaging its other end upon saidring, elongate spring elemerits each connected at one end with the underside of the poppet valve head and extending into the second chamber, andmeans connecting .the other ends of the spring elements with the body'ofthe thermal element.

References Cited in the file of this patent UNITED STATES PATENTS2,101,369 Jorgensen et a1. Dec. 7, 1937 2,419,630 Cruzan et al. ...5Apr.. 29, 1947- 2,536,642 Holley Jan. 2, 1951 2,757,650 Holley Aug. 7,1956v 2,847,165 Freismuth Aug. 12, 1958

1. A THERMOSTATICALLY ACTUATED VALVE UNIT COMPRISING A HOUSING, A PLATEMEMBER THEREIN AND DIVIDING THE HOUSING INTO A FIRST CHAMBER AND ASECOND CHAMBER, SAID PLATE MEMBER HAVING A CENTRAL OPERING THERETHROUGH,A FLUID INLET PORT AND A FLUID OUTLET PORT OPENING DIRECTLY INTO THEFIRST CHAMBER, A FLUID INLET PORT OPENING INTO THE SECOND CHAMBER, ASPIDER STRUCTURE SUPPORTED BY SAID PLATE MEMBER IN SAID SECOND CHAMBER,A THERMAL ELEMENT HAVING A BODY AND A PISTON CARRIED BY THE BODY ANDMOVABLE RELATIVE TO THE BODY BY THERMAL ACTION, A RESILIENT MEANSCONNECTED WITH SAID BODY AND SUPPORTING THE THERMAL ELEMENT ON THESPIDER, SAID PISTON BEING DIRECTED THROUGH SAID PLATE MEMBER OPENING, AVALVE POPPET POSITIONED WITHIN THE FIRST CHAMBER OVER THE PLATE MEMBERAND SUPPORTED BY THE PISTON AND MOVABLE THEREBY BETWEEN TWO EXTREMEPOSITIONS IN ONE OF WHICH POSITIONS IT ENGAGES THE PLATE MEMBER OVER THEOPENING THEREIN, AND IN THE OTHER OF WHICH POSITIONS IT CLOSES THE FLUIDINLET PORT COMMUNICATION WITH THE FIRST CHAMBER, SAID VALVE POPPET